Impact reduction apparel and impact absorbing liner for apparel

ABSTRACT

An impact absorbing liner apparatus and impact reduction apparel are disclosed. An impact absorbing liner has a size and a configuration, such as multiple extending impact absorbing members, which can be formed and shaped around a part of a wearer&#39;s body. The impact absorbing liner is at least partially obscured from external view by apparel worn over the part of the wearer&#39;s body. The apparatus further includes a rigid frame connected with the impact absorbing liner and having at least a distal end and a proximal end. The distal end and proximal end each have a connection mechanism to connect together to provide the size and the configuration for the impact absorbing liner, and to conform to the impact reduction apparel.

RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/241,696 filed Oct. 14, 2015, which is incorporated herein by reference in its entirety.

BACKGROUND

Just about every activity requires apparel, and sometimes very specific apparel, such as helmets and pads for skateboarders, in addition to standard shirts, shoes, pants, shorts, socks or any coverage that has potential for impact. Surfers often wear wetsuits. Skiers and snowboarders often wear helmets, while a number of snowboarders wear additional protection such as knee pads and wrist guards. As used herein, the term “apparel” refers not only to clothing, headgear or footwear, but also to accessories that can be worn by a person separately or with such clothing, headgear or footwear or legwear. Additionally, “apparel” refers to any covering for areas of impact on equipment or devices.

However, common impact reduction apparel, coverings or accessories are typically very bulky, cumbersome, and stand out too much for the tastes of their wearer. Thus, many people in certain activities will opt to not use any impact resistant products, which, while appearing more fashionable, put them at increased risk of injury from an impact while undergoing the activity. For example, skateboarders often eschew helmets in favor of trendy hats such as ball caps, beanies or trucker's hats. These hats provide nearly zero impact reduction.

For equipment applications, despite precautions and robust designs, the risk of an accidental impact is apparent and can be detrimental to the equipment's proper function. Shipping and storage of sensitive and fragile equipment can be an area of risk and is well suited for alternative coverings to avoid and minimize damage.

Accordingly, what is needed is impact reduction apparel that can be worn with other apparel, placed over sensitive equipment, and have a low profile, subtle appearance or be hidden altogether. Further, such impact reduction apparel can provide a platform for features that were previously impossible or very difficult to implement with conventional apparel.

SUMMARY

An impact absorbing liner for existing and custom apparel or other equipment is presented, as is apparel or accessories integrating such impact absorbing liner. The impact absorbing liner includes one or more layers of impact absorbing and/or abrasion resistant material. Each layer of impact absorbing material is sized and configured to be positioned over one or more critical areas of a wearer's body, which may be exposed to a risk of impact during an activity, lifestyle or equipment lifecycle. The impact absorbing liner further includes one or more connectors, for connecting various parts of the impact absorbing liner together and allowing the connection to be sized to fit any particular application. Each layer has a specific material designed for optimum comfort and impact reduction, abrasion resistance and overall product integrity.

Creases and peripheral profiles are configured to enable flat packaging and folding for storage when product is not in use. The impact absorbing liner can be formed to a unique profile that will conform to the inside of another piece of apparel or accessory, such as inside the user's headgear, or other head-covering equipment. A thin impact absorbing liner can be applied in strategic locations to reduce the risk of damage to apparel and equipment without the need for bulky apparatuses. The impact absorbing liner can be removable and used in several garments or can be permanently integrated into an apparel or equipment product.

One aspect of the present disclosure relates to a detachable impact absorbing liner for an item of apparel. The detachable impact absorbing liner may comprise an internal frame. The internal frame may have a trunk member. The trunk member may extend from a first portion to a second portion opposite the first portion. The trunk member may include a plurality of branch members extending laterally from the trunk member. The plurality of branch members may comprise a first end branch member and a rear end branch member. At least two of the branch members that extend from opposite sides of the trunk member may have side members extending laterally from a distal end of each of the at least two of the branch members. The internal frame may further include a clasping system. The clasping system may comprise a clasping mechanism on a distal end of each of the side members and on a distal end of each adjacent branch member of the plurality of branch members. The clasping system may enable the internal frame to be shaped and fastened in a shape to conform to a shape of a wearer's body part and to be positioned within an item of apparel for that body part.

The detachable impact absorbing liner for an item of apparel comprising two or more impact resistant layers. The two or more impact resistant layers may be coupled with the internal frame. The two or more impact resistant layers may comprise a polymer layer. The polymer layer may have a first density to resist puncture and tearing. The two or more impact resistant layers may comprise an inner impact absorbing layer having a second density to resist impact. The two or more impact resistant layers may cover a majority of the internal frame. The two or more impact resistant layers may be formed with cut-ins. The cut-ins may allow the two or more impact resistant layers to conform to the shape of the wearer's body when the internal frame is shaped and fastened in the shape conforming to the wearer's body.

In some variations the item of apparel may be a sock. The clasping system may cause the internal frame to be shaped and fastened in a shape to conform with a shin of the wearer. The item of apparel may be underwear. The clasping system may cause the internal frame to be shaped and fastened in a shape to conform with a pelvic region of the wearer.

One aspect of the present disclosure relates to a detachable impact absorbing liner for an item of apparel. The detachable impact absorbing liner may comprise a frame. The frame may have a central portion. The frame may have fingers. The fingers may extend from the central portion. The fingers may have clasping members extending substantially laterally away from the end portions of the fingers. The clasping members may be configured to clasp with clasping members of adjacent fingers. The frame may be configured such that when clasped the frame conforms to the shape of a wearer's body part.

The detachable impact absorbing liner for an item of apparel may comprise two or more impact resistant layers. The two or more impact resistant layers may be coupled with the frame. The two or more impact resistant layers may comprise a polymer layer having a first density to resist puncture and tearing. The two or more impact resistant layers may comprise an inner impact absorbing layer. The inner impact absorbing layer may have a second density to resist impact. The two or more impact resistant layers may cover a majority of the frame. The two or more impact resistant layers may be formed with cut-ins to allow the two or more impact resistant layers to conform to the shape of the wearer's body part when the frame is shaped and fastened in shape conforming with the wearer's body part.

In some variations, the impact reducing liner can be permanently integrated into the headgear, hat, head covering equipment, apparel, garment or the like. One or more impact reducing liners can be applied to apparel or an accessory to cover strategic areas as needed for a given application. Relief cuts can be applied in areas where flex and conformity is needed for proper function. Relief cuts can allow for improved conformity of the insert to the wearer's head or body. In some implementations, one or more impact resistant liners as described herein can be affixed to a hat or garment through pockets, stitching, hook and loop fasteners, adhesive, mechanical fasteners, rivets, or the like. Attachment methods can be applied to allow for removal of the impact resistant liner(s) for cleaning or maintenance or be intended as a permanent application.

In exemplary headgear applications a liner may be secured with a polymer tab for integration onto a central button or cylindrical device on the crown of said headgear. A polymer tab provides a rigid platform to secure a liner onto hat or garment through pockets, stitching, hook and loop fasteners, adhesive, mechanical fasteners, rivets, or the like. The tab may also allow free rotation about a pivotal axis to relocate the attached liner for a variation of applications. Such applications may include embroidery, cleaning, maintenance, additional components or the like.

The total number of inserts may vary to suit the need of specific application requirements. One exemplary application may yield a seam or gap in a designated location which allows for easy folding of the hat, garment or device for storage, shipping or other application needs.

The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects will now be described in detail with reference to the following drawings.

FIG. 1 is a section view of an impact absorbing liner with aeration holes;

FIG. 2 is an isometric view of an impact absorbing liner with flex/vent grooves;

FIG. 3 is a detailed view of the flex/vent grooves of an impact absorbing liner;

FIG. 4 is a plan view of an impact absorbing liner showing aeration holes;

FIG. 5 illustrates an adjustable clasp;

FIG. 6 illustrates an internal frame of an impact absorbing liner, inside looking out;

FIG. 7 illustrates an internal support structure of an impact absorbing liner;

FIG. 8 illustrates another internal support structure of an impact absorbing liner;

FIG. 9 illustrates a close-up view of a snap-fit detail of the internal support structure of an impact absorbing liner;

FIG. 10 is a plan view of an impact absorbing liner, inside looking out;

FIG. 11 is a transparent view of the assembly showing an integral internal frame;

FIG. 12 is an assembly view of an impact absorbing liner showing a close-up of a snap closure with adjustable features;

FIG. 13 is an isometric view of an assembly of an impact absorbing liner, inside looking out;

FIG. 14 is another isometric view of the assembly;

FIG. 15 is a plan view of the assembly of an impact absorbing liner, outside looking in;

FIG. 16 is an isometric section view showing integral internal structure within an impact absorbing liner;

FIG. 17 illustrates a rear view of an impact absorbing liner;

FIG. 18 illustrates a top view of an impact absorbing liner;

FIG. 19 illustrates another top view of an impact absorbing liner;

FIG. 20 illustrates arcs positioned on the outside profile for full coverage by an impact absorbing liner when installed, and also illustrates temple protection;

FIG. 21 illustrates integrated drawstring tubes;

FIG. 22 illustrates an integrated clasp for snap-back and strap back hats;

FIG. 23 is an exploded view of a layered configuration of an impact absorbing liner for headgear applications;

FIG. 24 is a two-dimensional profile showing an external shape and internal relief cuts;

FIG. 25 illustrates a headgear application as installed on a representative head. Relief cuts placed at areas of curvature to enable conformity to the surface; and

FIG. 26 is an exploded view of the base materials of an impact absorbing liner for lamination and prior to cutting parts.

FIG. 27 is an isometric view of an outer encapsulation device for an impact absorbing liner

FIG. 28 is an isometric view of an outer encapsulation device

FIG. 29 is an impact absorbing insert

FIG. 30 is a view of an exemplary liner insert profile with relief features

FIG. 31 is a view of a liner insert attached to a textile with margin for secondary attachment methods.

FIG. 32 is an exemplary view of a headgear application with impact reduction padding infused into the base textile.

FIG. 33 is an exemplary view of the inside of a hard shell headgear application

FIG. 34 is a view of an insert for hard shell headgear applications showing representative relief cuts and profile adaptations.

FIG. 35 is a view of an insert for hard shell headgear applications showing representative profile adaptations.

FIG. 36 is a view of an insert for hard shell headgear applications showing representative profile adaptations.

FIG. 37 is a view of an insert for hats showing representative relief cuts and profile adaptations for the front panel

FIG. 38 is a view of an insert for hats showing representative relief cuts and profile adaptations for the side panel

FIG. 39 is a view of an insert for hats showing representative relief cuts and profile adaptations for the back panel

FIG. 40 is an isometric view of a ball cap showing a representative chin strap adaptation

FIG. 41 is an isomeric view showing a representative clip to secure a chin strap to headgear.

FIG. 42 is an isometric view showing a close up of a representative clip to secure a chin strap before it is installed into a hat

FIG. 43 is an isometric view showing a close up of a representative clip and chin strap assembly joint before it is installed into a hat

FIG. 44 is an isometric view of a hat showing a representative installation adaptation for a chin strap loop between the sweatband and the outer fabric of a hat

FIG. 45 is an isometric view showing a representative adaptation of padded taping as typically applied on ball caps

FIG. 46 is an isometric view showing a representative padded taping before installation onto hat or garment

FIG. 47 is a view of an exemplary liner insert profile for front and side coverage with relief features

FIG. 48 is a view of a representative component to align and secure a liner while allowing free rotation

FIG. 49 is an exemplary view of a liner installed in a ball cap to provide front and side coverage

FIG. 50 is an exemplary view of a one piece liner secured into a representative headgear while allowing for rotation

FIG. 51 is an exemplary view of a liner installed in a ball cap and rotated 180 degrees to provide access to the front of the hat for embroidery or other customization

FIG. 52 demonstrates the components of an embodiment to secure in a hat or headgear through an exploded assembly view

FIG. 53 is a view of an exemplary liner insert for a 2 piece configuration; front insert shown

FIG. 54 is a view of an exemplary liner insert for a 2 piece configuration; back insert shown

FIG. 55 is an exemplary view of a 2 piece liner system installed in a ball cap

FIG. 56 is an exemplary view of a representative headgear with a dropdown secion in the back for additional coverage on the users head

FIG. 57 is an exemplary view of a 2 piece liner system installed in a ball cap with only the back panel shown

FIG. 58 is an exemplary view of a 2 piece liner system installed in a ball cap with only the front panel shown

FIG. 59 is an exemplary view of a 2 piece liner system installed in a ball cap and folded for shipping, storage or other applications

FIG. 60 is an isometric view representing a securing strap which wraps below the ears and around the back of the users head

FIG. 61 is an exemplary view of a securing strap which wraps below the ears and around the back of the users head installed on a representative headgear

FIG. 62 is an isometric view of a securing strap installed on a representative headgear with internal attachment mechanism shown in dotted lines

FIG. 63 is a view representing an exemplary configuration of a wraparound strap in a collapsed position when not in use

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This document describes an impact absorbing liner for existing and custom apparel and equipment. In one example, the apparel is headgear, such as a baseball cap or “trucker's cap” or beanies. The impact absorbing liner includes one or more layers of impact absorbing material. Each layer of impact absorbing material is sized and configured to be positioned over critical areas of a wearer's body, such as, but not limited to, parts of a wearer's head, which may be exposed to a risk of impact during an active lifestyle. The impact absorbing liner further includes one or more connectors, for connecting various parts of the impact absorbing liner together after the liner has been formed to confirm to the critical areas of the wearer's body, and allowing the liner to be sized to fit any particular application. One or more of the connectors can be self-adhering, or may have a connection mechanism such as a mechanical clasp (snap, button, zipper, Velcro, etc), or other mechanism.

The impact absorbing liner is wearable with other apparel or devices such that the impact absorbing liner is hidden or hide-able. The impact absorbing liner combines aesthetic design with impact protection, and can have one or more size adjustment mechanisms to allow for a universal fit.

In some implementations, the layers of impact absorbing material are rigid or semi-rigid, and can be made of so called “smart molecules” that harden on impact, open cell urethane foam rubber, closed cell urethane foam rubber, silicone elastomer, polycarbonate, Kevlar, textiles or the like, and formed to be worn with into custom and existing head gear or to fit a unique profile needed for a specific application. Accordingly, the impact absorbing liner combines aesthetic design with impact protection.

In a headgear application, the impact absorbing liner can be formed and shaped to fit at least partially or even completely within, various headgear such as helmets, hard hats, headbands, sweatbands, hoodies, beanies, skull caps, wigs, ballcaps (fitted, stretch-fit and adjustable), wetsuit caps, dry suit caps, scuba diving caps and hiking headgear. Other headgear and apparel can be used.

Other apparel applications include, but not limited to, temple protection (right or left as needed for batting and pitching applications), ear covers, elbow pads, t-shirts (long and short sleeve), sweaters, sweatshirts, undergarments (boxers, briefs, sports bra), booties, shirt or jersey with integrated sports bra, gloves, mittens, jeans, head socks (for positioning under helmet or the like), hiking boots, work-boots, designer boots, shoes, tennis shoes, running shoes, cleats, golf shoes, snowboarding boots, ski boots, socks with integrated padding in the shin, ankle or surrounding area, shin pads, ankle guards, or the like.

Applications of the impact absorbing liner can include equipment and commercial applications such as, without limitation, soccer shin guards, backpack, luggage, medical braces, casts, bandages, medical wraps, wrist guards, metatarsal insert, sole inserts, carpet padding, carpet, area rugs, blankets, seat covers, interior car side paneling, sensitive electronic cabinets, storage boxes, military communication systems, radar components, sonar components or the like. Regardless of application, the impact absorbing liner can be manufactured and shipped flat to minimize warehousing requirements for high volume applications or molded to specific form as required.

Impact Absorbing Liner:

In exemplary implementations, the impact absorbing liner can be designed to be integral with a headgear article, or removable to meet a variety of application requirements. The impact absorbing liner can be formed to stand freely on its own in a shape desired for end use. The impact absorbing liner can be configured to lay flat for streamlined packaging and shipping before use. The impact absorbing liner can be made from one or more layers of a variety of impact absorbing materials such as open cell urethane foam rubber, closed cell urethane foam rubber, silicone elastomer, Kevlar, polycarbonate or alike, and which can be formed of any thickness, density and profile to provide maximum impact resistance while remaining thin, light weight and low profile. The material can maintain elasticity, which can then be used as a fine adjustment and as a security feature to hold the impact absorbing liner in a desired position when in use.

FIGS. 1-63 illustrate exemplary implementations of the disclosed technology. In some exemplary implementations, as illustrated in FIGS. 1-63, an impact absorbing liner is provided for application to headgear. The headgear can include, without limitation, ball caps, beanies, hoodies, military style hats, equestrian hats, or the like. The impact absorbing liner can be either universal or one-sized, or custom designed for specific applications. For instance, snap back and fitted ball caps may both use one common size and design or vary as needed.

FIG. 1 is a cut-away section view of an impact absorbing liner 100 with aeration holes 102. The impact absorbing liner 100 includes cut-in sections 104 that define laterally-extending arms 106 or coverage regions 108 of the one or more layers of impact absorbing materials. FIG. 2 is an isometric view of an impact absorbing liner 200 with flex/vent grooves 202 that are formed into the one or more layers of impact absorbing materials. In some instances, the flex/vent grooves 202 can be used in addition to, or in lieu of, the aeration holes 102 through the impact absorbing liner 100. FIG. 3 is a detailed view of flex/vent grooves 302 of an impact absorbing liner 300, consistent with that shown in FIG. 2. Each flex/vent groove 302 can be formed into one or more of the layers of impact absorbing materials, preferably leaving at least one layer of the material intact.

FIG. 4 is a plan view of an impact absorbing liner 400 with aeration holes 402, and illustrating a preferred cut-out shape of the impact absorbing liner 400 in an un-assembled form, i.e. as cut with a die or pressed from a mold for shipping and prior to being formed into a semi-spherical shape to be worn as an impact absorbing liner for a piece of headgear, such as a hat or cap. The aeration holes 402 can be applied as needed based on a desired breathability of the selected material. If a solid gel elastomer is used, aeration holes can be applied to provide adequate ventilation and avoid overheating the user. Conversely, if a breathable open cell foam material is applied, the material itself will provide breathability and maximize the available surface area for the absorbing material.

FIG. 5 illustrates a portion of an internal frame having a fastening device such as an adjustable clasp 500 with recess 501 to allow for a flat assembly. Fasteners 502, which can be snaps, clasps, pins and corresponding holes, or the like, provide a mechanism with which to attach the frame creating and maintaining a curved shape. Slots 503 eliminate material where it is not needed for performance and allow reduced weight for the final assembly. The, adjustable clasp 500 may or may not be integral with the structural frame, and provides a foundation to fasten the entire assembly together. In some implementations, the adjustable clasp 500 can have a range of adjustability to cover the full range of adult and children sizes. In some implementations, the adjustable clasp 500 includes a snap-fit clasp that allows for easy adjusting while providing a secure closure. Elastic straps and or hook and loop fasteners can also be used in strategic locations, such as slots 503, to allow for a snug, universal fit of the impact absorbing liner, via adjustment of the structural frame, as needed.

FIG. 6 illustrates an internal frame 600 of an impact absorbing liner, inside looking out. First fasteners 601 secure the frame to maintain lateral shape and secure to the wearer's head. Second fasteners 602 secure the internal frame 600 to maintain circumferential shape and allow adjustability to secure to various head shapes and sizes. First and second fasteners 601 and 602 enable adjustments necessary to make the product universal to fit a range of head shapes and sizes.

FIG. 7 illustrates an isometric view of an internal frame 700 to provide a support structure of an impact absorbing liner. FIG. 8 illustrates a plan view of an internal frame 800 of an impact absorbing liner. The internal frame 700 or 800 can be formed of, without limitation, one or more of polycarbonates, Kevlar, fiberglass, polyethylene, polypropylene, vinyl, or the like and which provides puncture and abrasion resistance in addition to structural support for a self-supporting product. The internal frame 700, 800 also allows for a wider range of liner materials. For instance, using soft liner materials without an internal frame may weaken the assembly and hinder protection due to the liner material shifting around instead of staying in position.

The internal frame 700, 800 can be formed to spring out and conform to the shape of the apparel within which it is placed as needed to suit the specific application. Additionally, the internal frame 700, 800 can be pre-formed, using thermoforming or similar press process, to create a unique shape to which the softer, impact absorbing layers will conform. This provides a stable and standalone structure with a secure and contoured fit into the receiving apparel. By using the internal frame 700, 800, the assembly can be either removable or integrated within the impact absorbing liner during manufacturing. The internal frame 700, 800 also provides a base or foundation for the adjustable clasp for the user to easily store the impact absorbing liner when not in use and in a flattened configuration, for quick assembly when needed. The adjustable clasp also provides a mechanism to securely attach the liner to the area requiring protection.

In some implementations, the internal frame 700, 800 can include a locating hole to provide alignment points for use during over mold or assembly of the liner during the manufacturing process. These holes, in conjunction with the adjustable clasp, can ensure proper alignment of the assembly during manufacturing. The internal frame 700, 800 can be collapsible or manufactured in multiple parts to allow for quick folding and storage of the impact absorbing liner when traveling, shipping or not in use.

The internal frame 700, 800 adds an additional layer of protection to resist against punctures in strategic locations. The internal frame 700, 800 can also have thicker sections or multiple layers at strategic locations on the frame. Outer edges can be raised or corrugated to achieve the desired rigidity while minimizing added weight. The internal frame 700, 800 can also provide an alternative path for impact load dispersion. Instead of an impact being focused on the immediate contact area, the internal frame 700, 800 can act as a dispersion element and help absorb and dissipate the force.

In addition to thickness variations, the material properties can also be varied throughout the internal frame 700, 800. Inserting sections with higher elasticity properties, the versatility and adjustment of the frame is increased. The amount of mechanical adjustment needed can be reduced and replaced with elastic allowances and impact absorbing qualities in the material itself. Some applications may also require a more rigid section for either support or increased protection. This property can also be varied during internal frame manufacturing.

The internal frame 700, 800 can be formed or manufactured in various colors and textures to suit the branding and marketing demands. Color variations can be custom suited to various logos, applications and styles. Transparent and opaque shades can also be used for either demonstration purposes or for aesthetic reasons as needed. Texture can be varied as well to suit the specific application. Some textures will be better suited for adding layers or material, covering in cloth or other casing than textures used with the raw base material and inside another hat or garment. The internal frame 700, 800 can be made of a rigid or semi-rigid plastic, polycarbonate, polyethylene, polypropylene, vinyl, carbon fiber, a metal mesh, or metal wire, or the like.

The internal frame 700, 800 need not be “internal” to other layers of the impact absorbing liner, and can be applied to either exterior surface of the impact absorbing liner. This configuration can be applied in addition to the internal frame 700, 800 as mentioned herein and can serve to act as a hard shell for protection and rigidity. As an external frame, the frame can be made up of multiple sections to allow for increased flexibility. Each section can be mechanically attached and either be applied as a single piece or as multiple pieces. Multiple pieces of the frame can be hinged or connected together in a chain configuration where the rotational axis is aligned accordingly to provide flexibility in the desired direction and limit movement as needed.

FIG. 9 illustrates a close-up view of a snap fit of the internal frame 900 of an impact absorbing liner, in accordance with some implementations, and as substantially described above.

FIG. 10 shows a plan view of an assembled impact absorbing liner 1000, inside looking out. Undercut 1001, 1002 and 1003 allow space to accommodate for the thickness of a sweat band and maximize fit and comfort when inserted into a hat, for example. Adjustable clasp mechanisms 1004 and 1005 extend from the various extending members for allowing a customized fit. FIG. 11 is a transparent view of the assembly showing an integral internal frame 1100, and shows the over mold of the frame and the impact absorbing liner.

FIG. 12 is an assembly view 1200 of an impact absorbing liner showing a close-up of a snap closure with adjustable features. FIG. 13 is an isometric view of an assembly 1300 of an impact absorbing liner with integral support frame, from the inside looking out. FIG. 14 is another isometric view of an assembly 1400, from the outside looking in. FIG. 15 is a plan view of an assembly of an impact absorbing liner 1500, from the outside looking in.

FIG. 16 is an isometric section view showing integral internal structure within an impact absorbing liner 1600. The impact absorbing liner 1600 includes an internal frame having extending frame arms 1601 and 1602.

FIG. 17 illustrates a rear view of an impact absorbing liner 1700 as installed on the wearer's head. FIG. 18 illustrates a top view of an impact absorbing liner 1800 as installed on the wearer's head. FIG. 19 illustrates another top view of an impact absorbing liner 1900, in an assembled state.

FIG. 20 illustrates a side view (left side shown) of a folded impact absorbing liner 2000 and 2002. Temple protection 2001 can be fitted on the left or right side (left side shown). Arcs 2003 and 2004 fold and conform to mating curvature for full coverage when installed.

FIG. 21 illustrates integrated drawstring tubes (dotted lines) 2100. An integrated drawstring tube is represented within an impact absorbing liner placed in the front band, 2101, and side bands, 2102, of the product.

FIG. 22 illustrates a close up isometric view of the back of an impact absorbing liner 2200. An integrated clasp 2201 for snap-back and strap back hats maintains proper alignment and secure attachment when installed into a hat. Drawstring tube in the side band 2202 is further described in FIG. 21.

FIG. 23 is an exploded view of a layered configuration 2300 of an impact absorbing liner 2301 for headgear applications (additional layers can be applied) or other applications as needed. The impact absorbing liner 2301 includes a polymer layer 2302 to disperse impact loads and maintain structural integrity of the assembly. The polymer layer 2302 also resists puncture and tearing of the assembly. The impact absorbing liner 2301 further includes an inner impact absorbing layer 2303, and a breathable, moisture wicking fabric 2304.

FIG. 24 is a two-dimensional profile of an impact absorbing liner 2400 showing an external shape and internal relief cuts. The impact absorbing liner 2400 includes a back band 2401 that rests either inside of a sweatband of a hat, inside of a clasp on snap back hats or the like. The impact absorbing liner 2400 further includes a back ear member 2402 that provides extended coverage over the head with a tailored profile to offer a seamless transition between the back and side bands. Side band 2403 rests either inside of a sweatband of a hat or other method of securing in place. Side arm 2404 extends from the center portion of the product and connects the side band. Front ear member 2405 offers extended coverage over the head with a tailored profile to offer a seamless transition between the front and side bands. Front band 2406 rests either inside of a sweatband of a hat or other method of securing in place. This portion rests between the bill of a ball cap and the wearer's head. The front band offers coverage of the lower portion of the wearer's head and provides a mating edge for the front ear to provide maximum coverage. Undercut grooves 2407 to resist tearing and enhance movement when folded into a hemispherical shape as when worn on the head. The grooves shown are merely representative, and can be positioned throughout as needed to maximize folding effectiveness and coverage.

FIG. 25 illustrates a headgear application as installed on a representative head 2500. Relief cuts 2501 placed at areas of curvature to enable conformity to the surface. Remaining features as further described in FIG. 20.

FIG. 26 is an exploded view of the base materials of an impact absorbing liner 2600 for lamination and prior to cutting parts. The impact absorbing liner 2600 includes a cloth or performance fabric layer 2601, and an inner impact absorbing layer 2602. The impact absorbing liner 2600 further includes a polymer based semi rigid structural liner 2603. This liner provides lateral support, abrasion resistance and puncture resistance in addition to impact dispersion attributes. The impact absorbing liner 2600 further includes an outer impact absorbing layer 2604. Additional layers and combinations of polymer and impact absorbing materials can be applied as needed for a desired application.

FIG. 27 is an isometric view of an outer encapsulation device 2700 to support an impact absorbing liner. The outer encapsulation device 2700 includes cover portions 2703. Additional impact absorbing layers can be inserted within integrated pockets 2701. Elastic band 2702 secures the impact absorbing liner to the encapsulation device with an elastic band to tighten the complete assembly to the wearer's head. Another elastic band 2704 is similar to elastic band 2702, however operates as a mechanism to fasten additional impact absorbing inserts.

FIG. 28 is an isometric view of an outer encapsulation device 2800 similar to FIG. 27. Encapsulation device 2802 incorporates an elastic band 2801 to secure to the head of the wearer. Pockets 2701 can be incorporated as discussed above. Chinstrap 2803 provides an additional method of fastening the assembly to the head of the wearer.

FIG. 29 shows an impact absorbing insert 2900 of similar composition as outlined in FIG. 26. Insert can be fitted into a secure pocket 2701 and held in place with an elastic band 2704.

FIG. 30 shows an exemplary profile shape for a liner which can be infused or otherwise attached to headgear or apparel 3001. Relief cuts 3002 are representative locations for common headgear applications. The depth, width and length of these relief cuts can vary to suit the shape it is intended to conform to. Profile edge 3003 is representative of one attachment implementation where stitching can be applied to attach the liner to the headgear or apparel.

FIG. 31 shows a base textile 3101 with additional margin outside of the perimeter of the impact reduction insert 3102. This additional margin can be applied to create desired seams and stitching patterns as required for the intended design. Margin width can be tailored during sub-assembly manufacturing to further enhance and benefit the final headgear manufacturing process or for alternative applications as needed.

FIG. 32 is an exemplary headgear application where drop down member 3201 can be applied by the back of the head or skull to provide additional surface area to secure to the users head and provide additional coverage. Drop down member 3201 provides increased coverage to further protect the users head when combined with impact reduction materials. Drop down member 3201 can be an abrupt step or smooth transition as needed for optimal fit, comfort and aesthetics. Inner sweatband 3202 can remain at a consistent level or be contoured to follow the line of the drop down member 3201. Stitch seam attaching the inner sweatband 3202 to the hat or garment can be secured to the inner liner of the hat, garment or head gear to provide a smooth exterior panel that is not interrupted by visible stitching seams. Inside stitching seams can also provide an internal pocket 2701 for which the impact reduction liner can be inserted. Elastic band 3202 can be applied to further enhance a secure fit. The intersection of the bill or brim 3203 can be comprised of a breakaway joint or flexible hinge so that this rigid feature does not inadvertently dislodge or misalign the impact reduction liner from the critical areas on the user. Exterior textile 3204 can be flexible in one or multiple directions to allow for a secure and conforming fit for various users head shapes and profiles.

FIG. 33 is an exemplary application for hard shell headgear 3301. Ventilation holes 3302 can be increased in size, decreased in size, increased in quantity, decreased in quantity, remain the same or otherwise altered to suit the desired application. The resulting ventilation configuration can be a driving factor for the inner impact reduction liner insert 3303. The insert can be tailored to suit a full range of shell sizes and shapes without compromising the performance integrity of the layered impact reduction liner. Total number of layers of alternating foam, polymer sheeting, textiles and the like can be adapted to specific applications and fitment requirements.

FIG. 34 is an exemplary implementation of a liner 3401 as used in a hard shell headgear application or apparel. Relief cuts 3402 allow for increased flexibility and conformity to the inside of the hard shell. These relief features can also provide an additional means of ventilation flow. Contour profile 3403 can be applied to specific areas to allow for clearance and conformity to the users head. One implementation of a contour can be applied over the user's ear for additional clearance and comfort.

FIG. 35 is a view of an insert adaptation 3501 which can be applied to the crown of a hat or hard shell headgear.

FIG. 36 is a view of an insert adaptation 3601 which can be applied to the area of a hat or hard shell headgear that covers the back of a user's skull.

By having separate liners 3401, 3501, 3601, the thickness and layered material composition can be adapted to suit the application and not compromised to be universal. An additional benefit to having several inserts is the ability to maximize material stock during manufacturing thereby reducing production costs.

FIG. 37 is a view of a representative impact reduction insert for the front panel of a typical ball cap 3703. A liner can be secured using stitching, adhesive, pockets or otherwise fixed to the textile of the garment. A profile edge 3701 can be adjusted to suit various profile adaptations for any hat style and is not limited to ball caps. The profile edge 3701 can maximize the area covered by the impact reduction insert and offer a secure fit. Relief cuts 3702 offer a flow path for cooling and ventilation and provide stress relief in the impact reduction liner to allow for folding and bending in critical locations to optimize the fit and conformity to the users head. Relief cuts 3702 allow the impact reduction insert to effectively contour against the shape of various users heads. Angle, thickness, location and shape can be adjusted to suit specific applications and is not limited to headwear. Relief cuts 3702, can be applied to any garment or application where conformity to a curved surface is desired. Insert tongue 3704 offers continuous coverage for the front of the head when applied in headwear applications. An extrusion of insert tongue 3704 also provides a means to attach two front panels making them one continuous piece to minimize total components in a headwear or garment application. Integrating panels for one continuous panel provides additional surface coverage by relocating seams and gaps to less critical areas. Profile shape 3705 is designed to mate to and match the profile of extrusion 3704. Profile shape 3705 can provide maximum coverage while allowing the installed impact reduction insert to flex and move as needed during application and use.

FIG. 38 is a view of an impact reduction insert liner 3804 as designed for a side panel implementation for, but not limited to, a ball cap or the like. Insert liner 3804 can be secured using stitching, adhesive, pockets, etc., or otherwise fixed to the textile of the garment. The profile edges, 3802 and 3803, can be adjusted to suit various profile adaptations for any hat or garment style and is not limited to ball caps. The profile of edge 3802 can maximize the area covered by the impact reduction insert and offer a secure fit. Profile edge 3803 reflects a step down feature that can be applied to add additional material coverage and allow for a smooth transition to the back drop down member 3201. Relief cuts 3801 and 3802 provide a flow path for cooling and ventilation and provides stress relief in the impact reduction liner to allow for folding and bending in critical locations to optimize the fit and conformity to the users head. Relief cuts 3801 allow the impact reduction insert to effectively contour against the shape of various users heads. Angle, thickness, location and shape can be adjusted to suit specific applications and is not limited to headwear. Relief cut 3802 can allow folding of the hat or garment when not in use. The pattern can be applied to any garment or application where conformity to a curved surface is desired.

FIG. 39 is a view of a representative impact reduction insert for the back panel of a typical ball cap 3907. The insert or liner can be secured using stitching, adhesive, pockets or otherwise fixed to the textile of the garment. The profile edge 3903 and 3904 can be adjusted to suit various profile adaptations for any garment or hat style and is not limited to ball caps. The unique profiles of edges 3903 and 3904 can maximize the area covered by the impact reduction insert and offer a secure fit which conforms to the user. Relief cuts 3901 offer a flow path for cooling and ventilation and provide stress relief in the impact reduction liner to allow for folding and bending in critical locations to optimize the fit and conformity to the users head. Relief cuts 3901 allow the impact reduction insert to effectively contour against the shape of various users heads. Angle, thickness, location and shape can be adjusted to suit specific applications and is not limited to headwear. Relief cut pattern 3901 can be applied to any garment or application where conformity to a curved surface is desired. Insert tongue 3905 offers continuous coverage for the back of the head when applied in headwear applications. An extrusion 3905 also provides a means to attach two back panels making them one continuous piece to minimize total components in a headwear or garment application. Integrating panels for one continuous panel provides additional surface coverage by relocating seams and gaps to less critical areas. Profile shape 3906 is configured to mate to and match the profile of extrusion 3905. Profile relief cut 3902 allows for additional flexing when wearing or storing or folding or otherwise changing the shape of the garment or hat to which it is applied. FIG. 40 illustrates a ball cap with an attached chin strap 4003. The chin strap 4003 can be permanently affixed or removable to suit the intended use. The assembled product application can be applied to any garment or head gear to which the user needs assurance of a secure fit. Mounting locations 4001 can be placed anywhere circumferentially around the lower portion of the hat. An exemplary mounting application for the attachment points 4001 is to secure between the outer textile and the inner sweatband 4005. A strap can be configured with a single path 4003 or can branch off 4002 to offer adjustments to suit user needs and comfort. A clearance gap 4004 can be applied to allow clearance around the user's ear. The clearance gap 4004 can be open to the air or covered with a fabric, performance textile, impact reduction padding or any combination thereof to provide a means of additional coverage of the wearers ear.

FIG. 41 illustrates a clip 4101 that is secured into a hat or garment. The dotted line 4102 represents a stitching line which can pass through mating features on clip 4101 to allow for a secure attachment, while an attachment includes stitching, other mechanisms can be used, such as mechanical rivets, adhesive, hook and loop fasteners, clasps or the like, as needed to suit overall requirements of the product and application. Chin strap 4103 is shown as an exemplary use and integration of the strap 4103 to a mating clip 4101.

FIG. 42 shows an exemplary representation of a clip which can be applied to attach a chin strap 4003 and 4103 or other auxiliary component. The clip 4200 can be formed of any material, such as a textile, polymer, metal or any combination thereof as needed to suit the application requirements. Non-staining and non-corrosive materials are intended to protect the textile and user from contamination. Clip 4200 can be secured to a hat or garment using mating features 4203. Loop feature 4203 can be applied in any shape or configuration such as square, triangle, hexagonal, octagonal, straight, angled or the like to suit the intended application. Section 4202 can be used to secure the strap 4003 and 4103 or otherwise be used as an auxiliary attachment point on a hat or garment.

FIG. 43 is a close up view of a clip 4200 and chin strap 4304. Chin strap 4304 can be permanently affixed to the clip 4200 or remain removable as desired to suit the application. Gap 4303 can allow for access to remove the strap 4304 for the removable implementation. The size and profile of the gap 4303 can be tapered to provide an area of friction to help keep the strap 4304 properly in place when in use. Rings 4302 are an exemplary representation of a method by which the clip 4200 can be secured or otherwise affixed to a hat or garment.

FIG. 44 shows a close up view of a clip 4403 as integrated with, without limitation, a ball cap. In this application, the clip 4403 is secured into a hat or garment using the existing stich seam as applied to secure the inner liner or sweatband 4401 and the outer textile 4402 of a hat or garment. Clip 4403 can be applied at any distance from the bottom edge 4404 or remain hidden with no portion of clip 4403 being visible from the outside of the hat or garment. Bottom edge 4404 is shown during the transition from the front brim of a ball cap to the drop down feature 3201.

FIG. 45 shows an exemplary representation of impact reduction seam taping 4501 as applied to a garment or hat. Taping 4501 can be textile, foam, polymer or any combination thereof to provide impact reduction attributes. Material comprising the taping 4501 can be attached using stitching, adhesive, rivets, clasps, hook and loop fasteners or the like. Intersection 4502 represents an exemplary application where the impact reduction taping 4501 is affixed on the garment or hat between the inside liner or sweatband 4503 and the outer textile 4504. Layers applied to the impact reduction taping 4501 can range in thickness between 0.1 mm to 15 mm as needed for the intended application. Material layering can include, without limitation, impact reduction materials 2600.

FIG. 46 shows an exemplary representation of impact reduction seam taping 4601 which can be applied on hats, garments or the like. Taping 4601 can be textile, foam, polymer liner or any combination thereof to provide impact reduction attributes. Material comprising the taping 4601 can be attached using stitching, adhesive, rivets, hook and loop fasteners or the like. Taping thickness 4602 represents total taping material after subsequent layers have been applied to create the impact reduction taping 4601 and can range in thickness between 0.1 mm to 10 mm as needed for the intended application. Material layering can comprise of but not limited to impact reduction materials 2600.

FIG. 47 shows an exemplary profile of a one piece liner 4700 in a flat orientation. Relief cuts 4701-4703 enable the liner to collapse when inserted into apparel or headgear and conform to the shape of the mating surface while remaining flexible. Relief cuts 4701 and 4702 allow for minimal gaps between the edges of the liner when collapsed and inserted into apparel or headgear. Groove cut 4703 allows for additional flexibility in an area of curvature and provides a means for aeration and ventilation as needed. Holes 4704 allow for ventilation in designated locations and may provide a method to decrease overall mass of the liner. Holes 4704 may be arranged in a linear orientation or randomly scattered throughout the liner as needed for specific applications.

FIG. 48 illustrates a component which offers an attachment point for a flat liner 4700 and headgear 4900 and 5000. Edges 4801 may mate to a liner as a means of positioning and/or a means of attachment. Hole cut 4802 may be applied as an attachment point to integrate into apparel or headgear. Hole cut 4802 may vary in size and shape as needed for the intended application and may offer an axis for pivotal rotation of the liner 4700. Embodiment 4800 may be rigid polymer and range in thickness from 0.005″-0.25″. Impact reduction foam or equivalent materials may be applied to the surface of the component to provide additional surface coverage as needed.

FIG. 49 shows an exemplary implementation of liner 4700 and 4901 in a collapsed orientation when installed into headgear. Edges 4902 may be positioned and adjusted to provide coverage as needed for the intended application.

FIG. 50 shows an exemplary implementation of liner 4700, component 4800 and installation arrangement 4900. Attachment point 5003 is an exemplary location for means of mechanically joining component 5001 to headgear 5004. Seam 5002 illustrates a location where component 5001 and liner 4700 may be joined.

FIG. 51 shows an alternative configuration where a liner 5000 and 5101 may be positioned backwards through rotation about a pivotal axis 5103 for access to the front of a headgear 5102. The orientation of the liner as illustrated 5100 allows for access behind the liner without removal or destruction of the assembled components. Frontal access may be used for embroidery, cleaning, maintenance or the like.

FIG. 52 further shows an exemplary view of a liner 5202, attachment component 5203 and headgear 5201 mechanically secured with a button 5205 and pin 5204. Pin 5204 may provide a pivotal axis for rotation of the liner about the headgear. Pin 5204 may pass through component 5203 and 5201 and be secured within button 5205. In one implementation the component plate 5203 may be permanently attached to liner 5202 as to further constrain the components when fully assembled. Pin 5204 may be replaced with a snap or button to allow for removal of the liner in its entirety as needed.

FIG. 53 shows an exemplary profile of the front insert of a two piece liner 5300 in a flat orientation prior to installation 5500. Relief cuts 5301 and 5302 enable the liner to collapse when inserted into apparel or headgear. Relief cut 5301 allows for minimal gaps between the edges of the liner when collapsed and inserted into apparel or headgear. Window cut 5304 allows for additional flexibility in an area of curvature and provides a means for aeration and ventilation as needed. Holes 5305 allow for ventilation in designated locations and may provide a method to decrease overall mass of the liner. Holes 5305 may be arranged in a linear orientation or randomly scattered throughout the liner as needed for specific applications. Edges 5306 may be aligned to the folding seam of headgear for collapsed orientations 5900 to further enhance folding for storage and shipping when not in use.

FIG. 54 shows an exemplary profile of the back insert of a two piece liner 5400 in a flat orientation prior to installation 5500. Relief cuts 5401 and 5402 enable the liner to collapse when inserted into apparel or headgear. Relief cut 5401 allows for minimal gaps between the edges of the liner when collapsed and inserted into apparel or headgear. Window cut 5405 allows for additional flexibility in an area of curvature and provides a means for aeration and ventilation as needed. Holes 5404 allow for ventilation in designated locations and may provide a method to decrease overall mass of the liner. Holes 5404 may be arranged in a linear orientation or randomly scattered throughout the liner as needed for specific applications. Edges 5403 may be aligned to the folding seam of headgear for collapsed orientations 5900 to further enhance folding for storage and shipping when not in use.

FIG. 55 shows and exemplary implementation of front liner 5300 and 5502 and back liner 5400 and 5501 as installed in a representative headgear. Seam 5503 identifies a location where front liner 5502 and back liner 5501 may be joined. Edges 5503 may be aligned to the folding seam of headgear for collapsed orientations 5900 to further enhance folding for storage and shipping when not in use.

FIG. 56 is a profile view of an exemplary headgear as configured with a two piece liner 5500. The profile as shown may also be applied to alternative liner quantities and configurations as needed for an application. The drop down feature 5601 further illustrates the dropdown member 3201.

FIG. 57 is a view illustrating a representative installation of a back liner 5400 and 5701.

FIG. 58 is a view illustrating a representative installation of a front liner 5300 and 5801.

FIG. 59 is a view of a representative headgear in a folded configuration. Seams 5901 may be configured to align with the edges of a liner assembly 5503 to enhance folding. Folding may enable increased efficiency for storage, packaging, shipping or other applications when not in use.

FIG. 60 is an isometric view of a representative strap which wraps around the back of a user's head 6003 on the distal end. The proximal end may be contoured to provide clearance around the front of a user's ears 6001. Strap may be permanently attached or mechanical fastened at attachment point 6004. Mechanical fasteners may be configured for permanent installation or allow for strap removal. Mechanical fastening methods may include rivets, hooks, loops, Velcro, adhesive, stitching or the like. Attachment point 6004 may contain a cut or recess 4303 to mate to a fixed loop 4302 as shown in representative configuration 4300. Mating feature 6002 may be rigid or elastic. In rigid form, feature 6002 may contain snap features or male and female mating attributes to mechanically secure the strap 6003 and allow for adjustment. In some implementations, the mating feature 6002 may be comprised of elastic material which may stretch to adjust and contour to a user's head shape.

FIG. 61 illustrates an exemplary implementation of a wraparound strap 6102 attached to a ball cap at an intersection 6101. Attachment method may be comprised of loops 4200 which may be secured as shown in FIG. 41.

FIG. 62 further illustrates a representative attachment configuration whereby loops 4200 and 6201 are secured to a headgear 6202 and provide an attachment point for a strap 6203 and 4003.

FIG. 63 shows embodiment 6200 in a collapsed configuration. The configuration as shown may be applied when the functionality of strap 6301 is not required or for storage, shipping or other applications. In some implementations, attachment point 6302 may enable a secure attachment mechanism for strap 6301 which provides a pivotal axis. In other implementations, attachment point 6302 may enable removal of strap 6301.

The one or more layers of impact absorbing material can be encased in fabric, fused onto fabric or otherwise mated to a fabric liner to suit any particular application and aesthetic considerations. The fabric liner can be made from any fabric material, and can include antibacterial components to minimize the spreading of germs during heavy use. The fabric liner can also be washable, mold resistant, water resistant (either inherent from the base material or combined with a hydrophobic coating), and can include other components, such as metallic threading for radiation shielding, structural strength, and other features. The fabric can be breathable and offer moisture wicking qualities to support drying during and after use and when washed.

In some implementations, the impact absorbing liner is configured and formed of multiple density materials fused or otherwise connected together in a multi-ply configuration. This configuration provides additional application flexibility. For example, by having an outer layer (farthest from the body of a wearer) that is dense and rigid, an inner layer can be softer, less dense and less rigid, allowing for a more comfortable fit without sacrificing protection. Additionally, a rigid layer can be interposed between two or more non-rigid layers. Further still, the rigid layer can be implemented as a series of “bones” that form a “skeletal” structure, which is in turn surrounded or layered on top and/or the bottom by non-rigid layers. The rigid layer can fully cover the part with consistent thickness or have variable thicknesses and contours as needed for specific design requirements. The layer can be different from the other layers in size and shape or it can be identical to the non-rigid layers as needed for specific applications.

A thickness of the impact absorbing liner can also be varied or variable to suit a wide range of activities and applications. The thickness can also be varied within the same liner to provide custom protection without compromising weight. The profile can be adaptive and variable from one area to another area. For instance, thinner and lighter sections can be applied where impact is unlikely, while heavier profiles can be strategically positioned in high impact areas for maximum impact dispersion without adding overall weight. One example would be to protect high impact areas of the skull, such as the temples and where the spinal cord and skull meet.

As discussed above, the impact absorbing liner can be shaped to maximize head coverage for high-risk areas on a wearer's body. Accordingly, in some implementations, a profile of the impact absorbing liner has grooves and protrusions in strategic locations to focus in the protection where it is needed most to maximize impact dispersion while keeping areas with low impact risk as light-weight as possible. In still other implementations, an impact absorbing liner can be reversible to maximize versatility and adjust the impact resistance and/or comfort provided by the impact absorbing liner.

The impact absorbing liner can be permanently affixed to an item of apparel, such as integrated into fabric of the apparel, integrated into layers of the apparel, etc., provided with an exposed adhesive layer for user installation or can be removable though the use of mechanical fasteners, hook and loop straps (such as Velcro® or the like), zippers, snaps, clips, clamps, vice, or the like. In one example, an impact absorbing liner for headgear can be formed to use the headgear's existing sweatband as an anchor. Still, other containment mechanisms for the impact absorbing liner can be used. The impact absorbing liner can include one or more connector attachment points, which allow for easy adjustment using any of a variety of connection mechanisms, such as Velcro, snaps, buttons, serrated bands, etc. The impact absorbing liner is configured to be interchangeable, and therefore is highly versatile and easy to use among various applications. The impact absorbing liner can further include padding, which can be permanently or transiently affixed to an inside surface (i.e., a surface closest to a body of wearer), for more custom fitting, as well as added protection. The impact absorbing liner can be manufactured in various colors and textures to suit the branding and marketing demands.

An outer encapsulation device can be implemented to form the impact absorbing liner as described herein. Encapsulation device offers a means to utilize the impact absorbing liner without the need for a separate hat or headgear. Integrated pockets can be applied to provide a method of inserting additional impact absorbing layers as needed for a specific application. An elastic sweatband can be applied at the base of the device to secure the impact absorbing liner and provide an adjustable mechanism to attach to the head of the wearer and further secure the impact absorbing inserts. Encapsulation device can be fitted with a chinstrap that is either permanent or removable providing an additional method to secure the assembly to the head of a wearer.

Integrating Padding Into Headgear:

Headgear comprised of an impact absorbing liner sewn in, fused on, adhered to, affixed within a pocket, hook and loop fastener or otherwise inserted or attached to the exterior textile. In some implementations an impact absorbing liner can be applied to custom or existing headgear applications before, during or after initial manufacturing. One exemplary application to fasten the liner to the headgear is by stitching or sewing around the outer perimeter of the liner padding. Stitching can be applied directly adjacent to the padding for a more secure fit or be left with additional room if greater flexibility and movement is desired. Padding can be loosely placed on the headgear prior to stitching or can be attached using adhesive film to enhance performance and durability of the final assembly.

Panels can be assembled prior to stitching into the required headgear orientation by adhering fabric patterns to specifically designed impact reduction pads. This method allows for pre assembly to reduce the manufacturing duration of the headgear article and provides a margin of fabric that can be easily fastened to other textile materials.

Primary textiles can be comprised of a woven composition that provides structural integrity for the overall shape desired to suit the design as well as provide a stretching attribute to further secure the article on a user's head. Another exemplary method of securing headgear to a user's head is through an elastic band, draw string or the like.

Headgear can be altered or tailored during design and manufacturing to offer additional coverage for the back of the skull, temples or other critical areas as needed for specific applications. Additional coverage will offer increased surface area protection which can further be secured through elastic textiles or additional bands as needed. Extended coverage over the occipital lobe of the wearers head can be localized or applied with a smooth transition taper from the front brim. Additional coverage can be curved slightly or utilize elastic bands to further secure the hat, headgear or garment to the wearers body. Adaptations can offer adjustment for which the user can tailor the product to suit their needs or be configured during manufacturing.

Coverage for the impact absorbing liner can be tailored to specific areas of a user's head to suit high risk locations or to meet desired application requirements. Specifying intended performance or high risk impact zones will provide a foundation to maximize performance and maintain a balance of unnecessary materials and weight. This process of localized coverage can be applied using the same process and materials for a wide array of coverage applications; therefore increasing manufacturing efficiency while remaining adaptable for new and unique applications.

In one exemplary implementation, a hard shell can be applied as needed for additional protection in specific locations. The thickness of the shell can vary to suit applications however an anticipated range can be, but not limited to, 0.01″ thru 0.25″. This method can be particularly useful for baseball or other similar applications where a projectile can impact a user's head.

Another exemplary application is through localized material thickness and density adaptations. Implementing unique material density, thickness and layered attributes will further enhance the performance for specific applications while minimizing overall weight and bulkiness of the finished product. This method can be particularly useful for applications where the wearer is prone to impact in a predictable area such as in skateboarding, roller-skating, rollerblading, or other wheeled applications where a common impact can be realized on the back of the skull. This method can also be applicable to users with medical conditions causing sudden balance or equilibrium disturbances resulting in loss of control and/or falling.

Impact Dispersion Bill or Brim:

Many existing hat designs integrate a rigid or semi-rigid bill or brim. While this is functional for its intended purpose of blocking light it can also provide a leverage point which can dislodge or inadvertently remove the headgear from a user's body. When considering impact reduction applications, keeping the headgear securely in place is a critical component.

In some implementations, the bill or brim of a headgear article can offer impact dispersion attributes. Bill or brim can be made from impact reduction padding, be designed with a break-away joint, utilize a living hinge or the like.

Use of impact reduction padding for the bill or brim can provide additional impact reduction coverage and can remain flexible. By remaining flexible in strategic locations, the brim can remain functional as originally intended but also offer a feature to further secure the headgear and as to not be forced off of a user's head in the case of an impact.

Implementation of a break-away joint can allow the headgear to remain in the desired place on a user's head during an impact by dislodging the bill or brim at the critical time of impact leaving the remainder of the headgear in place as designed. Another implementation is through the use of a living hinge. A living hinge is defined as a joint which offers a weak joint specifically designed to release in the case of an impact. Applying this feature to the bill or brim of headgear can allow a reusable design which will minimize the risk of the headgear falling off during an impact.

Ventilation Holes:

In some implementations, holes, cuts, grooves and the like can be applied to optimize heat transfer from the user's body and offer a ventilation path. These features can be designed to add aesthetic appeal as well as weight reduction.

Hard Shell Headgear:

In some implementations, the layered impact reduction padding can be applied to the inside of a hard shell such as applied for helmet applications. The impact reduction liner can be fastened to the shell through stitching, adhesive, hook and loop fasteners (such as Velcro® or the like), encased in textiles or the like. Layered impact reduction liner can be used in place of traditional foam to offer increased performance and implemented in the same manner as current design. Liner can range in thickness to suit desired performance requirements. Common adaptations will range in thickness from, but not limited to, 2 mm thru 30 mm.

As required from the applications performance requirements and thickness criteria, multiple layers of alternating foam, polymer sheeting, textiles, and the like can be applied to tailor the performance and weight to specific attributes. One or several layers can have an extruded profile to offer additional load distribution surface area, cooling channels, aesthetic and tactile benefits or the like.

Flex Grooves:

In some implementations, the impact absorbing liner includes one or more grooves, channels, indentations, or the like, (“grooves”) placed or arranged in strategic locations on one or more surfaces, i.e. the inner surface, which allow for a smoother shaping and contouring to a body part of the wearer, and to provide flexibility or flexure to the impact absorbing liner for better conformance to various body shapes and sizes. The grooves also provide a unique profile for impact dispersion by allowing room for the material to flex, thereby absorbing additional force. The grooves further provide a path for air circulation to enhance breathability and reduce moisture during use.

Casing:

The impact absorbing liner can further include a casing, in accordance with alternative implementations. The casing can surround only the outer, inner or all around the impact absorbing liner to suit any particular application and/or aesthetic needs. Colors and patterns can be added and can include logos or other branding elements as needed. The casing can be made from puncture-proof, puncture-resistant, cut-proof, or cut-resistant materials, such as Kevlar thread, Teflon thread, carbon fiber threading, or the like. The casing can be interchangeable among one or more impact absorbing liner for sanitary or aesthetic needs.

One or more reinforcement frames can be applied or located where needed to provide specific protection for desired applications. This provides increased protection where it is needed for a specific activity to balance product weight, impact reduction, acceleration reduction and rigidity for the intended application.

Tightening System:

A tightening system such as a drawstring or cable can be applied for a low profile fastening mechanism that is easily adjustable to fit the user, and can be released for flat storage or transportation. Channel tubes can be integrated into the layers of the product or manufactured as part of the frame to provide seamless looping for the drawstring. Integral tubes eliminate the need for exposed or raised channels or grommets for the drawstring, and minimize stress concentrations on the users head, body or other specific application. Fastening and adjustment can be made using a knob lever or static friction groove.

The tightening system can be applied for circumferential adjustment and/or to control the height for a customized fit. A full coverage lattice arrangement can be applied to provide full coverage and maximum adjustability. Multiple fastening points can enable further adjustment and customization for the user.

The fastening device can also be operated by pinching a latched assembly. A serrated insert can slide freely when the latched assembly is pinched open, and lock when released. Allen wrenches or other tools can be used either in conjunction with the pinch-activated fastening device, or independently. The fastening device can also include a rotating knob to wind a tightening cord, and can be applied either to the liner or as part of the frame. The rotating knob includes a disk that is turned by hand and has a low profile. Allen wrenches or other tools can be used either in conjunction with the knob system, or independently.

Adjustment is provided in circumferential and/or vertical planes or directions, for universal fit for all head shapes and sizes. Accordingly, the impact absorbing liner can be easily adapted to varying sizes of body parts, such as varied head roundness, width, length or other dimension. The flexibility of the material can provide further for fine adjustment and a snug, secure fit.

Alignment Holes:

Holes can be placed in strategic locations for aiding assembly by providing alignment guides. In some implementations, the alignment holes can be unique or universal to utilize the existing aeration holes (as previously described). A size of the holes can be customized to adapt to existing manufacturing jigs, and the holes can be located for additional attachment points. The alignment holes can also be strategically located throughout the part to allow stress relieve over a contoured area of the body or equipment being protected. This can minimize bunching and increase the overall surface area coverage on complex and contoured areas.

Folding Parts:

By folding each component within the part, the total number of parts within the assembly are reduced. Creases and outside profiles are configured to enable flat packaging and folding for storage when product is not in use. This profile can conform to the inside of the user's headgear, outside of the head or other configurations as needed for the application.

The shape and profile of the impact absorbing liner provides maximum coverage when worn or applied on the users body (via headgear or apparel) while allowing for a universal fit that is adjustable for adult and youth sizes. The versatile design ensures full coverage for strategic locations. Thickness and density of protective layers are provided and can be varied in specific locations to support performance objectives for intended applications.

In some implementations, the profile, material thickness and densities employed in the impact absorbing liner are adaptable to fit within the sweatband of existing or custom headgear as to not require a larger or replacement hat, garment or other covering to properly use. Arcs on the “wing” sections of the part provide increased surface coverage when folded into the headgear or garment and in general for highly contoured surfaces.

Strategic cuts can be placed in the part to encourage conformity when applied to curved surfaces. In one example, the headgear liner has cuts on the wing sections to conform the users head shape. This conformity can provide additional and complete coverage compared to not having relief cuts. Relief cuts placed at areas of curvature to enable conformity to the mating surface.

Adhesive Layers:

One or more wet or tacky adhesive layers can be applied to attach several layers of varied thicknesses and densities. In some implementations, a dry adhesive can be heat sensitive which can allow for easier final alignment before “setting” in position. An adhesive can be installed via sheet/spray/film/etc. is applied before or after profile cutting.

Adhesion for each layer can occur before part cutting to simplify assembly. Where required, adhesive is applied after part cut out or before cut out. If assembly of the parts is required after cut out, a release liner is applied to the adhesive layer to allow for proper alignment and storage prior to final assembly.

Snap-Back Clasp:

A clasp can be integral or provided separately to fasten the liner to the existing clasp on snap-back hats. The clasp on the product can be low profile as to be universal for multiple hat applications and not limited to snap-back hats. The clasp maintains alignment and provides a mechanism to fasten the liner within the headgear or hat.

The clasp can be mechanically attached to the liner using adhesive, rivets, clamps, sewing, hook and loop attachments (i.e. Velcro), or the like. Additionally, the clasp can be permanently vulcanized to the foam or inner frame.

Temple and Spinal Guard:

The impact absorbing liner can be positioned below the hat line to offer additional coverage over the temple. Applications include, but not limited to, baseball base coaches, sporting coaches, baseball pitchers, baseball catchers, golf or any activity where a projectile could contact a user's temple. A temple guard can be applied on either the left or right side, and can be formed of the multiple layer technology described herein. One or more additional outer shells can be applied to provide additional protection. If an outside shell is used, it can provide a foundation to contour the guard to match the users head profile for a custom or form fitted part. An area of the user's body where the skull and spinal cord meet can have a multi layered protective protrusion to protect against a direct impact to the back of the head.

Layered Material:

In some implementations, an article of manufacture includes a layer of impact absorbing material followed by a rigid or semi-rigid layer, followed again by another layer of impact absorbing material. Additional layers of similar composition can be added and affixed to the assembly as needed to achieve the desired thickness and impact reduction performance.

The impact absorbing material can be made of “smart molecules” that harden on impact, open cell urethane foam rubber, closed cell urethane foam rubber, silicone elastomer, polycarbonate, Kevlar, textiles or the like, and formed to fit the unique profile needed for a specific application.

The material can be provided in sheets of varying length and width dimensions, rolls of varying widths, patterns or the like as needed for a specific application. Material can be manufactured with or without fabric, with or without adhesive exposed for attaching to substrate, equipment or coverings or the like.

Each layers thickness can be custom tailored for specific applications. The Impact reduction material thickness can range from 0.5 mm to 15 mm and density can range from 5 lb/ft̂3 to 50 lb/ft̂3. The denser layer can be placed on the side of the impact but can also be aligned on the inside liner which contacts the protected surface. The less dense layer can be placed on the side of the protected surface but can also be arranged on the side of impact. Multiple layers of impact reduction mater and rigid substrate can be applied in various sequences to suit the specific application. A dense layer of impact reduction material can be placed directly onto a less dense layer of impact reduction material creating a unique performance characteristic. Rigid liner substrate can be applied in multiple locations as needed for the application.

Individual Insert:

In some implementations, an article of manufacture includes a contoured hard outer shell and layered impact absorbent liner inside. The impact absorbent liner can have an integrated intermediate frame, formed of different materials or densities, the same material or densities, or any combination thereof. A contoured shell can be flexible or pre-formed to match the contour of the mating surface. In one exemplary application for headgear, the hard shell can be shaped to fit the inside of a hat or the contour of the head. A shape of the impact absorbing liner can vary to suit a desired application. Each application can consist of several individual shapes of the same or different dimensions as needed to suit the application.

The individual inserts can be attached to an existing garment or structure as to not be visible from the outside. Individual inserts can be applied independently or in a sequence as to provide partial or full coverage as needed for the application. An attachment mechanism can be permanent or removable as needed for the application. Attachment mechanisms can include, but not limited to, wet adhesive, dry adhesive, rivet, snap, button, zipper, hook and loop fastener, interlaced string, sewn, vulcanization, or the like.

Rotating Assembly

In some implementations, the embodiment can be secured using a mechanical fastener such as a rivet, pin, rod, button or the like to hold components together while allowing free rotation about a pivotal axis. Total rotation can be free of any restriction or confined to a angular constraint as needed for a specific application. In one exemplary application, the rotation of a liner may allow for access to the inner portion of a headgear that would otherwise be covered by a liner. This access may allow for embroidery, repair, cleaning, maintenance or other customizations as needed. The embodiment may be rotated or configured back to the original orientation as many times as needed over the life of the component. The embodiment can be further constrained using mechanical fasteners such as Velcro, snaps, buttons, stitching, adhesive or the like as to prevent unintended rotation during storage, shipping or active use.

Securing Strap:

A securing strap may be applied as an additional method of securing headgear to a user's head. The securing strap can be permanently integrated into the liner or headgear or be removable. Either configuration may utilize mechanical fasteners such as rivets, Velcro, hooks, loops, snaps, buttons, or the like. Straps may be fixed length or be adjustable. Methods for adjustability may include elastic bands, elastic fabric, snap features, buttons, clasps, or the like. The securing strap may be configured to wrap around a user's chin or around the back of the head. For the back of the head configuration, the strap may be sized and positioned as to rest just below the occipital lobe or on the back of the head. The straps may be configured to allow for easy removal or may be positioned out of the way while not in use. In some implementations when a strap is positioned out of the way it may remain attached to the headgear.

Miscellaneous:

The impact absorbing liner can include a loop applied to the side, front or rear edge of the assembly to allow for attachment to a belt or bag when not in use. The loop can be attached using a mating hook, loop or carabineer. The loop can be integral to the internal structure or attached to the final assembly using adhesives, button, snap, clamp or sewn in.

Automatic adjustment can be achieved using a slide-lock, rotational-lock, or other interval locking device. The interval locking device is designed so that adjustment is easily achieved while in use but does not have adverse protective or aesthetic affects from protrusions, which can cause a point load and risk injuring the user on impact. Adjustment can also be achieved using a removable tool.

A gripping material can be applied to either the inside or outside of the impact absorbing liner as needed to ensure a secure fit on the user's head or piece of equipment during extreme use. The gripping material can be integral with the liner manufacturing or added on as a post manufacturing feature. The gripping material can be a firm elastomer which is formulated to provide maximum adherence especially during active, cold, hot, wet, dry, dusty and other environments.

The impact absorbing liner can also include one or more of reflectors, lights and glow-in-the-dark or other luminescent materials (“light features”), which can be applied for customizations and for safety during low light use conditions. The light features can be arranged to enhance branding, logos, or otherwise custom graphics as needed or desired, and/or applied in zone-based locations to enhance visibility during a particular sport or activity.

The impact absorbing liner can further include one or more accessory mounts for electronic devices, phones, cameras, computers, data collection devices, storage devices, sensors, Global Positioning System (GPS), headphone attachments, speakers, or the like.

Electronic Adaptations:

The impact absorbing liner can include a radio frequency (RF) protection liner that can be applied as a coating or physical liner. The RF protection liner can be integral with the impact absorbing liner, provided as a casing or as a separate add-on product. RF protection liner can be affixed using the structural frame for a secure fit.

In some implementations, the impact absorbing liner can include one or more sensors can be connected with or integral with any part of the impact absorbing liner, to measure and record G-forces, forces of impact, speed, elevation changes, geo-positioning or location data, impact data, biometric data such as heart rate, body temperature, breathing rate, calorie consumption, calories burned, or the like. The sensors can be configured to communicate wirelessly or via wired connection to a smartphone or computer device for monitoring by medical staff or spectators while worn by the user. A data connector, such as a universal serial bus (USB) connector, can be adapted to download recorded data.

Lighting can be integrated into the liner by layering within the material during manufacturing, incorporating into the internal frame or the like. Lighting can be light emitting diode (LED), liquid crystal display (LCD), or any other light emitting mechanism. The lighting can be powered by external batteries, rechargeable power source, solar panels or the like. The lighting can be placed in any direction as needed for the application. Placement can be, but not limited to, head lamp, side indicators, back indicators or the like. Applications include but not limited to hiking, biking, walking, running, jogging, sports, hobby projects, camping, baseball, football, hockey, skateboarding, reading, or the like.

A wireless communication connectivity such as Bluetooth or other can be provided for head phone or cell phone connectivity, and for controls for media devices for hands free convenience. Wireless communication can also be used to communicate biometric data from the impact resistant liner to a mobile device or storage device.

A self-correcting mechanisms can be integrated to enable automatic resizing and automatic placement for ease of use and interchangeability. Solar panels can be applied to power integrated sensors or for external devices such as phones, watches and computers. Headphones, hearing aids and microphones can also be integrated as an add-on or integrated into the apparel design for specified user communities and applications.

Although a few embodiments have been described in detail above, other modifications are possible. Other embodiments may be within the scope of the following claims. 

1. A detachable impact absorbing liner for a hat, the detachable impact absorbing liner comprising: an internal frame having a trunk member extending from a frontal portion to a rear portion, and a plurality of branch members extending laterally from the trunk member, the plurality of branch members comprising a frontal branch member and a rear branch member, at least two of the branch members that extend from opposite sides of the trunk member having side members extending laterally from a distal end of each of the at least two of the branch members, the internal frame further including a clasping system comprising a clasping mechanism on a distal end of each of the side members and on a distal end of each adjacent branch member of the plurality of branch members, the clasping system enabling the internal frame to be shaped and fastened in a semi-spherical shape to conform to a shape of a wearer's head and to be positioned within the hat; two or more impact resistant layers coupled with the internal frame, the two or more impact resistant layers comprising a polymer layer having a first density to resist puncture and tearing, and an inner impact absorbing layer having a second density to resist impact, the two or more impact resistant layers covering a majority of the internal frame and being formed with cut-ins to allow the two or more impact resistant layers to conform to the shape of the wearer's head when the internal frame is shaped and fastened in the semi-spherical shape.
 2. The detachable impact absorbing liner in accordance with claim 1, wherein the two or more impact resistant layers include a breathable, moisture-wicking fabric attached to the inner impact absorbing layer.
 3. The detachable impact absorbing liner in accordance with claim 1, wherein the internal frame is interposed between the polymer layer and the inner impact absorbing layer.
 4. The detachable impact absorbing liner in accordance with claim 1, wherein the internal frame is formed of polycarbonate.
 5. The detachable impact absorbing liner in accordance with claim 1, wherein the two or more impact resistant layers include a plurality of aeration holes.
 6. The detachable impact absorbing liner in accordance with claim 1, wherein the inner frame includes a set of channels formed in the trunk member and/or in one or more of the plurality of branch members.
 7. The detachable impact absorbing liner in accordance with claim 1, further comprising an attachment mechanism for attaching the impact absorbing liner to an internal cavity of the hat.
 8. The detachable impact absorbing liner in accordance with claim 1, further comprising an additional internal frame, where two or more impact resistant layers are disposed between the two internal frames.
 9. The detachable impact absorbing liner in accordance with claim 1, further comprising a chin strap configured to secure the detachable impact absorbing liner to the wearer's head.
 10. The detachable impact absorbing liner in accordance with claim 1, further comprising an outer encapsulation device having cover portions attached to the two or more impact resistant layers and internal frame with one or more elastic bands.
 11. A detachable impact absorbing liner for an item of apparel, the detachable impact absorbing liner comprising: an internal frame having a trunk member extending from a first portion to a second portion opposite the first portion, and a plurality of branch members extending laterally from the trunk member, the plurality of branch members comprising a first end branch member and a rear end branch member, at least two of the branch members that extend from opposite sides of the trunk member having side members extending laterally from a distal end of each of the at least two of the branch members, the internal frame further including a clasping system comprising a clasping mechanism on a distal end of each of the side members and on a distal end of each adjacent branch member of the plurality of branch members, the clasping system enabling the internal frame to be shaped and fastened in a shape to conform to a shape of a wearer's body part and to be positioned within an item of apparel; two or more impact resistant layers coupled with the internal frame, the two or more impact resistant layers comprising a polymer layer having a first density to resist puncture and tearing, and an inner impact absorbing layer having a second density to resist impact, the two or more impact resistant layers covering a majority of the internal frame and being formed with cut-ins to allow the two or more impact resistant layers to conform to the shape of the wearer's body when the internal frame is shaped and fastened in the shape conforming to the wearer's body.
 12. The detachable impact absorbing liner in accordance with claim 11, wherein the two or more impact resistant layers include a breathable, moisture-wicking fabric attached to the inner impact absorbing layer.
 13. The detachable impact absorbing liner in accordance with claim 11, wherein the internal frame is interposed between the polymer layer and the inner impact absorbing layer.
 14. The detachable impact absorbing liner in accordance with claim 11, wherein the internal frame is formed of polycarbonate.
 15. The detachable impact absorbing liner in accordance with claim 11, wherein the two or more impact resistant layers include a plurality of aeration holes.
 16. The detachable impact absorbing liner in accordance with claim 11, wherein the inner frame includes a set of channels formed in the trunk member and/or in one or more of the plurality of branch members.
 17. The detachable impact absorbing liner in accordance with claim 11, further comprising an attachment mechanism for attaching the impact absorbing liner to an internal cavity of the item of apparel.
 18. The detachable impact absorbing liner in accordance with claim 11, wherein the item of apparel is a sock and where the clasping system causes the internal frame to be shaped and fastened in a shape to conform with a shin of the wearer.
 19. The detachable impact absorbing liner in accordance with claim 11, where the item of apparel is underwear and where the clasping system causes the internal frame to be shaped and fastened in a shape to conform with a pelvic region of the wearer.
 20. A detachable impact absorbing liner for an item of apparel, the detachable impact absorbing liner comprising: a frame having a central portion and fingers extending from the central portion, the fingers having clasping members extending substantially laterally away from the end portions of the fingers, the clasping members configured to clasp with clasping members of adjacent fingers, the frame configured such that when clasped the frame conforms to the shape of a wearer's body part; two or more impact resistant layers coupled with the frame, the two or more impact resistant layers comprising a polymer layer having a first density to resist puncture and tearing, and an inner impact absorbing layer having a second density to resist impact, the two or more impact resistant layers covering a majority of the frame and being formed with cut-ins to allow the two or more impact resistant layers to conform to the shape of the wearer's body part when the frame is shaped and fastened in shape conforming with the wearer's body part.
 21. The impact absorbing liner in accordance with claim 11, where additional coverage for the occipital lobe, as applied to ball caps or other headgear equipment, can aid in securing the garment to the wearer and offer increased coverage area.
 22. The impact absorbing liner in accordance with claim 11, where additional coverage for the temporal lobe, as applied to ball caps or other headgear equipment, can aid in securing the garment to the wearer and offer increased coverage area.
 23. The impact absorbing liner in accordance with claim 1, further comprising a mechanical fastener that allows rotation about a pivotal axis for access between the liner and apparel.
 24. The impact absorbing liner in accordance with claim 1, further comprising a mechanical attachment applied to further secure headgear to the users body and may be applied either under the wearers chin or behind the head. 